Machine for producing tufted fabrics



Oct. 15, 195? w. Y. ROBE ETAL MACHINE FOR PRODUCING TUFTED FABRICS 3 Sheets-Sheet 1 Filed March 16, 1955 lNVENTORS WALTER Y. ROBB HAROLD 1.. BLANCHARD ATTORNEY Get 15, 195? w. Y. ROBE ETAL,

MACHINE FOR PRODUCING TUFTED FABRICS 3 Sheets-Sheet 2 Filed March 16,, 1955 S B R B O O T R W Y V R V m m hi A .m. .L. a. 7 m..- w t a. a. a. e "z .2 emf-A" III HAROLD L. BLANCHARD ATTORNEY Get, 15, 195? w; Y. ROBE HAL. 2,009,000

MACHINE FOR PRODUCING TUFTED FABRICS 5 Sheets-Sheet 5 Fil ed March 16, 1955 ""QUHHH I77 y uu m lillflillllilllllllllllllllflllllllllli lllfllllllllllllllllllllmlllllllllli llnnlnllllllllllplqnlu INVENTORS WALTER Y. ROBB HAROLD L. BLANGHARD ATTORNE United grates Fatent MACHINE FOR PRGDUCING TUFTED FABRICS Walter Y. Robb, Whitinsviile, and Harold L. Blanchard, Milibury, Mass, assignors to Crompton & Knowles Loom Works, Worcester, Mass., a corpcration of Massachusetts Application March 16, 1955, Serial No. 494,778

37 Claims. ((11%. 11279) This invention relates to improvements in machines for forming tufted fabrics such as are suitable more particularly though not necessarily for floor coverings and it is the general object of the invention to provide such a machine, and also a method of operation, capable of producing a fabric having a fancy pattern.

Machines have been developed heretofore for the production of tufted fabrics by a punching operation, but such machines are not ordinarily adapted to the manufacture of tufted fabrics having a fancy pattern. It is an important object of the present invention to provide a machine operating with a series of pile yarn carriers each having its own supply of differently colored yarns and wherein the supplies are moved one at a time to a tuft forming position. In this way each cross row of tufts can have any desired color arrangement independent of the other rows so that the finished product can have an almost limitless variation of pattern and color.

it is a further object of the invention to provide a machine of the type already mentioned wherein each carrier when arriving at the tuft forming position will have free tuft ends extending therefrom in such position as to per mit the preforming of a row of tufts before the latter are applied to the backing fabric. After the row of tufts are preformed they are cut from their supply and are then pushed into the backing fabric.

it is a still further object of the invention to provide a machine of the type mentioned wherein the operation of preforming of tufts is followed by a movement of the yarn carrier in tuft forming position such as will draw off enough yarn for the next row of tufts to be formed from the carrier. The previously mentioned cutting operation occurs after the pull off operation.

it is a further object of the invention to provide a tuft fabric making machine with yarn control means operating in two stages, the first stage effecting the aforesaid preforming and the second stage, occurring after the tuft cutting operation, inserting the bights of the tufts into the backing fabric. The first stage as shown herein is accomplished by a tuft former which passes into guide cans and the second stage is effected by needles or the like 'slidable within the tuft former.

In order that the various carriers of the series may be placed in tuft forming position they are arranged on a chain or conveyor mechanism traversing a path close to the tuft forming position and it is a further object of the invention to coordinate the movements of the conveyor mechanism and the aforesaid control means so that the latter can cross the path traversed by the carriers while the latter are relatively stationary in order to form the tufts and then be withdrawn from the path to permit the next carrier to move into tuft forming position.

After the tufts are attached to the backing fabric they are still in the guide means where they might interfere with the next tuft forming operation. In order to clear the guide means of the tufts it is another object of the invention to effect relative movement between the last Fatented Oct. '15, 15357 formed row of tufts and the guide means. As shown herein this result is accomplished by rotating the guide means, preferably when the backing cloth is being advanced.

The backing fabric is fed around a nose bar which is so shaped as to place parts of the backing successively at a tuft forming station aligned with the tuft forming position of the free ends of the carrier being operated upon. It is the further object of the invention to form this bar with recesses which register with the previously mentioned needles, the parts of the nose bar adjacent to the recesses supporting the backing to prevent distortion thereof when the cut tufts are pushed into the backing.

Each carrier of the series is provided with a spool on which tuft forming yarns are wound, these yarns being of any desired color, and the yarns lead from the spool down through tubes and project as free ends beyond the tubes. These tubes are formed with side guides at their lower ends to prevent objectionable lateral displacement of the free ends and it is a further object of the invention to provide the previously mentioned tuft forming means with slots to receive the yarn guides of the tubes.

In order that the invention may be clearly understood reference is made to the accompanying drawings which illustrate by Way of example the embodiment of the invention and in which:

Fig. 1 is a side elevation partly in section of a machine made according to the present invention, part of the structure being shown diagrammatically, and certain of the parts being broken away,

Fig. 2 is an enlarged view similar to a part of Fig. 1 but showing the parts in a different position,

Fig. 3 is a detail horizontal section on line 33, Fig. 2, on an enlarged scale,

Fig. 4 is a vertical section on line 44, Fig. 3,

Fig. 5 is a fragmentary vertical section on line 55, Fig. 3, showing certain tufts already inserted into the backing cloth and indicating by full and dotted lines how the preformed tuft is pushed into the backing cloth,

Fig. 6 is a vertical section on line 66, Fig. 5, showing a part of the guides which assist in forming the tufts,

Fig. 7 is a vertical section on line 77, Fig. 2,

Fig. 8 is a rear elevation looking in the direction of arrow 8, Fig. 1, on an enlarged scale,

Fig. 9 is a rear view looking in the direction of arrow 9, Fig. 1, showing part of the main shaft of the machine and the cams thereon,

Fig. 10 is an enlarged vertical section on line 10-10, Fig. 1,

Fig. 11 is an enlarged vertical section on line 1111, Fig. 10,

Fig. 12 is an enlarged view looking in the direction of arrow 12, Fig. 2, showing the tuft cutting mechanism in two positions,

Fig. 13 is a diagrammatic view showing an electric circuit for controlling the locking mechanism for the carrier system,

Fig. 14 is a view looking in the direction opposite to that of Fig. 1 showing a mechanism for rotating the tuft guide means,

Figs. 15, 16 and 17 are diagrammatic views showing successive positions of the yarn guide means as it turns to clear itself of a row of tufts which has just been inserted into the backing cloth,

Fig. 18 shows diagrammatically a series of yarn carriers as an illustration of one way in which the yarns on the carriers can be arranged to produce a fancy pattern, and

' Fig. 19 is a detail vertical section on line 19-19, Fig. 10.

The machine to be set forth in more detail hereinafter,

to tuft forming position; advancing mechanism B'for the conveyor system; the backing cloth feed. system E which supplies a preformed sheet of material into which the tufts arepunched; yarn control mechanism .F which preforms tufs from the free yarn ends of the carrier in tuft forming position and then pushes the preformed tufts into the backing cloth; positioning mechanism G for the control means F; tuft cutting mechanism H; and tuft yarn guide mechanism K which' cooperates withth'e mechanism F to preform tufts and then moves to clearthe tufts which have been pushed into the backing cloth.

Certain of these means and-mechanisms-either extendacross'themachine, orare present on each side of'the machine, but except as otherwise "noted the following de tailed description will be limited principally to structure at one or the other'side in .order toavoidduplieation.

'Referrin'gtoiFig. 1, the-machine includes side plates 1' and'2which'are held together in any'approved manner-as by cross girts Arranged--atthefrontof-the machine; -the-left-hand-part thereof'as viewed in-Fig'; l, is the conveyor system-A which includesasupporting structure designated generallyat 4-having'an upright 5 and a cross beam.6. Suspended from the--beam -6-'is a bearing member 7 for-a pullover-shaft- 8,'there;being :one' of these bearings at each side of the-machine; To the" front of shaft 8 'are other bearings 9 which support a'shaft 10.- The-shaft 8 isprovided-at each-end thereofwith' a sprocketwheel 11 and each sprocket wheel meshes'with an endless conveyor chain 12 having double links 13 alternating with single links 14, see Fig. 10. The chains extend around guide 'rolls 15 on shaft 10 downwardly and under other guide rolls '18 on another shaft 19'. The

shafts 17 and 19 may be journaled in any approved man'-" net and thechain will ordinarily be kept taut so as to rei spend to any movement-of the sprocket wheels '11, The

rear parts of the chains have vertical runs 21 as shown? in Fig. 1. A catwalk 20-may be located at the front of the machine for the convenience of the machine opera tor, see Fig. 1.

Spaced along the chainsare tuft yarn carriers generally indicated'at 25"eachof which may be made for instance as shown in Fig. 11. Each carrier comprises'a lengthwise bar 26 to each end of which is secured a hanger 27 fastened at 28 to one'of the double links 13, i

see Figs. 10' and 11. The hangers at each end of the bar 26 support for rotation a spool 29 on which is wound" a series of pile yarns'Y arranged side by side on the spool. The yarns pass downwardly through tubes 30' which are secured to the bar 26 and a brace 31 for stifiening the bar is secured to the latter and also to the'tub'esi Thelower ends of the flat sides of each tube 30 extenddownwardly therefrom to form two guides 32, one on each side of a yarn passing through the tube. The guides 32 prevent lateral displacement of the depending. free ends 33 of the yarns in the tubes. The yarns Y may be of any desired color to provide the required pattern in the finished product and are wound on the several spools to meet the pattern demands.

lever 39 rockable on hub 40 of the pawl, see Figs. 10 andl9. A spring 41 normally holds the pawl against; the ratchet wheel. The front end of a connector rod'42;-

pivots on a stud 43supported by lever 39 and the-rear end of the rod is pivoted at 44 to a lever 45 rockable; on a fixed pivot 46. Lever 45 :is operated by. a cam-47 secured'to fireman shaft 48 of the loom. This shaft Spring pressed gudgeons 34 on the spools fit into the hangers to afford means for may be rotated in any approved manner and preferably Cam'47 also has a second incline 50 to give the chains an additionalmotion. The rocking .of lever 45 .ina clockwise direction under action-of cam 47- is in two steps the first of which, eflfected by incline 49; is much larger than the. second and acts to move the next carrier of the series to a tuft forming position designated at C, Fig. 2. After certain operations to be described hereinafter have taken place the incline50 causes the tube frame to move up a short distance to a pull off position C1, Fig.2, to pull ofl? yarn for the next operation of the carrier. The cam 47 then 'rockslever 45 back to place the.pawl.37 in position for its next advancing operation with respect to the ratchet'35 and the sprocket wheels.

11.j For each complete rocking of the lever 45 the chain will be moved linearly a distance equal-to the distance between adjacent carriers 25.

. The-backing cloth feed system for the backing cloth to, which-the tufts are applied includes-acloth roll 55' 01. which the ground or backing cloth'56 is wound, the latterextending around guiderolls 57 andthen forwardly to a positioning bar or beam 58'which extends across and isfixed to the sides-of the machine. This bar is supportedin positiom in the loom-by stands 59'which are bolted at 60 to the machine frame and thebar has a downwardlyand forwardly-extending upperplate 61 and a downwardly and rear-wardlyextending lower plate 62. The cloth 56 extends-forwardly along-plate 61, then aroundnose' 63- of-the"bar 58' and 'then downwardly and rearwardly al'ong the plate 62 to-a takeup roll 64 whichrmay be driven intermittently in'any approved manner. The roll 64 is stationary during the tuft forming operation as will be described and thenuponcompletion of the tuft ing-operation the roll 64 turns slightly to move the back ingcloth- 56 a sufiicient distance to present a new area thereof to the nose at the tuft forming station S.

7 From: the takeup roll 64 the tufted fabric goes over a guid-roll-65 and thenceto a cloth roll 66 which may be driven in any approved manner. The cloth 56 therefore unwindsdn a step-by-stepmotion from the roll 55, passes forwardly in front of and engagement with the bar 58' through the tufting-station-S, and thencerearwardly to the takeup roll 64 from'which' it is'led to the-windingup-roll 66. V

Thebar' 58 is provided with a' series of horizontally arrangedrecesses'70-located between-webs or fins 71 which support the ground fabric 56 between the recesses at the tuft forming station-S. The under side of plate 62 is provided with a series of shallow grooves 72'*leading downwardly and rearwardly from the 'recessesin' the direction of -travelof cloth '56 toward roll6'4. As will be described, the tufts which have been inserted into the fabric 56 project'into' their respective recesses170 and then as the tufted fabric moves rearwardly the tufts passalong the grooves 72'so that they may remain inserted in-the cloth without being acted on by forces which might otherwise tend to push them'back through the cloth.

The yarn control-mechanism F is located in front ofthebar 58-and-is supported by an I beam 75 extending across-the machine and secured to the end plates land 2.. Ateach end of thel -beam there is a slide bearing sup-. port means 76' and since these means are both :alikei'only.

onelQfthem-will bedescribed, see Figs: 1, 2,7 and -.8.

The bearin'gmeans 76.-includes a housing. 77 havinga top,rand-bottom;78 and 79'respectively and a vertical side her 84 has top and bottom plates 85 and 86 respectively engaging the upper and lower sets of rollers and has a side wall 87 which supports pins 88 on which rotate upper and lower inner sets of rollers 89 and 90 respectively. Each wall 87 extends rearwardly at 91 and a lengthwise bar 92 fixed to the parts 91 extends across the machine. Secured in the bar 92 is a fiat elongated tuft former 93 the rear edge of which is formed with teeth 94 separated by vertical transverse slots 95. The teeth 94, the tuft former 93, the bar 92, the parts 91 and the walls 87 and 89 and 9t thereon are therefore a unit slidable back and forth on the sets of rollers 81 and 82. Each wall 87 has a forwardly extending arm 96 pivoted at 97 to a lever 98.

Between rollers 89 and 90, see Fig. 7, is an end slide plate 99 the rear end of which connects with a push bar 100 extending across the machine and moving with each slide plate 99. Secured in push bar 100 and extending rearwardly therefrom is a set of needles 1111 which are blunt on their rear ends as shown in Fig. 5 and are slidable in holes or bores 162 in the tuft former 93. These holes pass through the teeth 94 as shown in Fig. 3. The front end of each end slide plate 99 is pivoted at 103 to a lever 1G4. Levers 98 and 104 are pivoted at 105 on bearing arms 166 secured at 107 to I beam 75.

The rear end of each tooth 94 is formed with a rounded cavity 198 adapted to receive a tuft yarn, and grooves 109 extend forwardly from the cavities in both the top and bottom faces of the teeth.

The positioning means G for the tuft control means F includes the two levers 98 and 104 and their respective cams 110 and 111 secured to shaft 48. These cams operate cam levers 112 and 113 connected by rods 114 to levers 98 and 104 respectively. Cams 110 and 111 are very similar throughout the greater part of their contours so that the tuft former 93 and needles 101 move together for the greater part of their horizontal sliding motion. When the tuft former 93 and needles 101 are in the position shown in Fig. 2, however, the tuft former 93 comes to rest and shortly thereafter the needle push bar 100 has an additional rearward motion.

The tuft cutter mechanism H includes a thin cutter blade 115 which is secured to a horizontal bar 116 each end of which is secured to a collar 117 fastened to a transverse reciprocable horizontal rod 118. One end of this rod and the associated parts are shown in Fig. 12. The bar 118 has each end thereof mounted for endwise sliding in a bearing 119 fixed with respect to the machine, only one of these bearings being shown in Fig. 12.

Secured to the main shaft 48 is a cam 120 having a cam groove 121 which receives a roller 122 on the lower end of a lever 123 pivoted on a stud 124 held stationary with respect to the machine by a stand 125 secured to the machine, see Figs. 1 and 9. The upper end of this lever 123 has a roll 126 which fits into a groove 127 in the collar 117. When the cam 120 oscillates the lever 123 the cutter blade will be moved from the full line position to the dotted line position shown in Fig. 12 and then back to the full line position. The time and cycle of operation for action of the cutter will be described more fully hereinafter.

The tuft guide mechanism K extends across the machine and includes upper and lower guide bars 130 and 131 respectively between which extend a number of thin vertical webs or spacers 132 which define between them guide channels 133 to receive the teeth 94 of the yarn control means. The slots 95 between the teeth receive the webs as indicated in Fig. 3. The two bars 130 and 131 have their outer surfaces 135 arcuate about a longitudinal axis which is central with respect to the two bars. A support stand 136 extending across the machine has secured thereto a center bearing 137 having an upper concave surface 138 to fit the curved surface 135 of whichever of the two bars 13% and 131 is in low position, see Fig. 5.

The bars 130 and 131 are joined at their ends by cross 7 heads one of which is shown at 140 in Fig. 6. Each cross head has a gudgeon 141 rotatable in a fixed bearing 142, one of the gudgeons and bearings being shown in Fig. 6. The axis of the gudgeons is the same as that of the curved surfaces 135.

Fixed to one of the gudgeons 141, see Fig. 14, is a gear pinion 145 and a holding wheel 146 having recesses 147 on opposite sides thereof to receive a resiliently mounted holding roll 148. When the roll 148 is in one or the other of the notches 147 the bars 130 and 131 will be disposed with their channels 133 horizontal and in position to receive the teeth 94.

A gear wheel 150 of twice the size of gear pinion 145 meshes with the latter and is mounted on a shaft 151 supported by the machine frame. Fixed with respect to the gear 150 is a ratchet wheel 152 which in the present instance has four teeth 153 to receive a pawl 154 pivoted at 155 on a lever 156 rocking about the shaft 151. Lever 156 is connected by rod 157 to a lever 158 movable about a fixed stud 159 and having the free end thereof positioned by cam 160 fixed to the shaft 48. The parts just described are so proportioned that an incline 161 on the cam 160 will cause the pawl 154 to give the ratchet wheel 152 and the gear 150 a one-quarter rotation in the direction of arrow b, Fig. 14, for each rotation of the shaft 48, resulting in a one-half rotation of the gear pinion 145 and the bars 130-131 through the successive positions shown in Figs. 15-17. After this rotation has been completed the holding roll 148 will keep the bars 130131 in the position to which they have been moved as the pawl 154 has its return motion.

Fig. l0 shows one end of the shaft 8 and associated parts including a bearing member 175, additional to bearing 7, held in fixed position on the machine and having a magnetic disc 176 secured thereto in fixed position. An electromagnetic brake coil 177 close to disc 176 is secured to and rotates with shaft 8 by reason of parts 178 and 179, as shown in Fig. 10. During rotation of the shaft 8 as already described the coil is deenergized but as soon as its angular movement is completed the coil becomes energized to prevent further accidental turning of the shaft.

A circuit for energizing the coil 177 is shown diagrammaticaily in Fig. 13 and includes a switch 180 opened and closed by a cam 181 which makes a rotation for each tuft forming operation of the machine. This cam has two high areas 132 and 183 which when under the switch open the latter to deenergize the brake during rotation of the shaft 8. When the high areas pass beyond control of the switch the latter close and the coil 177 then becomes energlzed from a source of electric power designated generally at 185. The brake mechanism of itself forms no part of the present invention other than providing means tor locking shaft 8 when it is intended to be at rest and any other form of brake can be employed. The electromagnetic brake is deenergized whenever lever 45 moves to advance the carrier system.

Preparatory to operation of the machine the ground cloth 56 will be placed in the machine and extended around the bar 58 and then connected to the takeup roll roll 64. The various spools of the diiferent carriers in the conveyor chain will also have been wound to produce the desired pattern. In Fig. 18 four carriers 1, II, III, IV are shown with four difierent kinds of yams indicated, although it is to be understood that the color of yarns can be selected in any Variety desired. In Fig. 18 the four yarns are indicated by heavy and light solid lines and heavy and light dotted lines, the yarns being arranged on their spools so that when they are moved successively to tuft forming position they will produce the desired pattern. The spools are then connected to the hangers of the various carriers in their correct order. Although only four yarn carriers are shown in Fig. 18 it is to be under- 7 a 7 stood thatanydesirednumbermay be useddepending upon manna of pattern to be produced. 7 7

With all of the carriers provided with spools and with the ground cloth 56in place the operation of themachine may be assumed to begin with a carrier in the position shown in Fig. 1 and with the tuft yarn control mechanism F retracted in'forward'. position anda given crosswise area of ithefa bric Seat the tufting station. Thefree ends will" hang .down from the carrier and be aligned by the: depending, sides 32T 'of thetubes on thecarrier. The cams 112-and: 1131 will then move the tuft former and'also the needles rearwardly to the positionshown in Fi I. 2, the slots 95 'receiving' the. guides 32fland't he teeth94ion the tutt -former engaging their respective freeend s-and pushing them through the guide channelsrl 33f to preform .the freeends into tufts and push them-against those parts of theground cloth. 55. opposite the recesses 70.. As' the teeth 94 pass into the channels l33 lcavities 108lwilljreceive-the free endsof the yarn andhold them in position for the. preformingoperation, and the sides of the tufts willentergrooves 109. The tuft lever 45 will then. be rockedIa. slight amount by cam 4 l tovlift the carrier a short'distance sufficiently to pull off enough yarn from itsspool for the next tuft forming operation of the carrier. when -th e teeth arefully in position as shown in full lines in 5 there is enough friction exertedagainst the preformed tuft to cause rotation of .the spool when the corresponding. carrier is given its pull-01f motion. It is found that the free ends, although drawn across the edge of the cutter blade, will not only not be cut by the blade but will be held by it during the pull off operation. During .the time the advancing mechanism is moving the con- Veyor system one of the high points 182-183 will open the switch 189 to deenergize the holding coil 177. Assoon as the. conveyorsystem has moved sufliciently to pull otfthe proper amount of yarn the switch 180 will again close to energize coil l77 to hold the shaft S against accidental turning. Cam 129 then acts onlever 123 to move the rod L118 longitudinally to draw the lower sharpened edge of the blade 115 across the tuftyarns to cut them from their spool.

Cam 111 their acts to rock lever 104 "to move the needles 101 rearwardly through the teeth 94 and against the hights of their respective preformed tufts and push the bights from the fullline position, Fig. 5, through the ground cloth 56 partway into the recesses 70 to the dotted line position, Fig' 5. Cam 111 then retra'ctsthe needles to'their' normalposition with respect to the teeth 94', after which both cams 11 3 and lllrock their levers 9 4 and 104' respectively to move the tuft former and needle structure forwardly 'out'of the path traversed by the carriers-'The switch 18% is again opened'and cam 47 'operatingthrough lever 45 and the structure shown in Fig. 19 advances the chain system until the'next carrier, the one below the carrier previously in tufting position, has been lifted to a position where its free ends are placed for the next tuftforniing operation. The switch 180" then closes.

As soon as the teeth 94'havebeen fully withdrawn from between the bars 130' and 131 the cam pointiol; see Fig. 14', Willcause rotation of the guide bars'from the position shown inFig; 14 through the'successive' positions showndiagrammatically inPigs; '17 and will continue the rotationuntil the bars have been-givena one-half turn. This turning of the-bars results in'clearing-them and channels133. of the rowof tufts previously 'inthe channels, and the. latter will be ready for thenext tuft forming operation- During the turning of the bars130 and 131 thetakeup roll 64 will move the fabric'56 so that the previously formed row of tufts will move downwardlyin the same direction in which the adjacent parts of the bars130 or 131 move, and these two" movements, occurring, together, insure furthenremoval of the tuftsf'r'om the channels I33. Afresh area'of thebacking'cloth56 is nowat'th'e tuft forming station and-the operation can berepeated:

' Asthe-tufted part of the ground fabric'56 movesaway from th e"tuft"forming station the bigh'ts of the tuftsal'." will move along'the' grooves 72 and will' therefore. not" be acted'pn by any force tending t0pushltl1em'back'; through thefbacking cloth56. The'fabric When'takeni from the cloth roll 66"can'have the, back thereof treated. with any" convenient or. appropriate? form". of adhesive which will secure the bights ofthe'tufts to the backingfab'= rictoholdithe tufts firmly imposition. 7

From theforegoingit will be seen that the invention? sets forth a machine wherein tuft fabrics'ofthepunchedj type can be made'with practically unlimited"pattern' designs; Any pattern which'itis desired to reproducecan be. determined by. the. order in which the .yarns are arranged on thetspools according to their color;or.other characteristic, .and as many'carriers can'b'e'providedasfi are necessaryforrepeat of the pattern.- The free'ends of yarn extending from the'carrier in tuft formingposition are'first' preformed intot tufts by cooperation of the? tuft'formingjmeans and theguide mechanism K, after which'thetufts' are cut'from their spooliand then'pushedi into the backing .clothiby the'needles During'the pulling off 'operationthe *freeends' may be held partly by fric tional'engagement between their bights and the'backing; cloth as established by the rear ends of the teethj94 andt'o some extent'frictional engagement of. the sides of the tufts by the 'bars and 131? Also, it is found that the edge of the knife along which the tuft ends extend toward their spoolnot only does not cut the yarns but assists in holding them against retrograde'movement dur ing the pullingotfoperation. The tuft forming mechanism is moved between adjacent carriers for its tuftforming operation and then is moved out'of'the path traversedby. the carriers to permit 'the next carrier to move into tuft forming position. 'Any convenient form of'backing, such as a Latex compound,[can be used to secure the bigh'ts of the tufts to the backingcloth56; The invention also'sets. forth'an improved method which includes the preliminary steps of winding the spools according to the desired pattern andthen after the spools have been applied to the chains acting on thefree ends to form tufts which are inserted into the backing cloth subsequent to the cutting operation. 7 Having now particularly described and'ascertained'th'e nature of the invention and'in what manner the same is to be performed, what is claimed is: V

1. In a machine for applying pile tufts to a backing, fabric which moves to place parts thereof successively at: a tuft forming station during operation ofthe machine, a series of carriers each provided with a supply of tuft -pile yarns having free ends, advancing means operating intermittently. to'move the carriers along a pathto locate them in a given order and one ata time in'tuft forming position for an interval of time, controlmeans for said.- free ends normally out of said path, positioning means to move the control means across said path during. one

of said intervals and cause the. control means to move. the free ends of the carrier in said tuft forming position. to positions 'adjacent'to the ground fabric, the advancing means being thereupon effective to move the carrier, in. tuft forming position to pull off pile yarn, cutter means: thereafter effective to cut said free ends from said carrier, the positioning means thereupon causingthe control means. to push the cut off free ends through that partrof thev ground fabric at said station, said positioning means there-.

- upon moving the control means. out of. said path, andthe advancing means thereupon moving the carriers along, said path to locate the next carrier in said series in'said; tuft forming position while said control means. is; out of. said path preparatory to another tuft forming operation: of. the machine.

2. The machine set forth in claim 1 whereinthe car riers' are mounted onendless chains and the vadvancing. means is 'operatively connectedfto the chains.

3. The machine" set forth in claim 1 wherein the, car-- riers are mounted on chains operatively connected to the 9 advancing means and a carrier in tuft forming position 15 supported by vertical runs of the chains and the free ends depend from the carrier and the control means moves horizontally.

4. In a machine for applying pile tufts to a backing fabric at a tuft forming station, feed means operative to move portions of said backing fabric successively to said station, a series of carriers each provided with a supply of tuft pile yarns having free ends, advancing means operating intermittently to locate the carriers in a given order and one at a time to a tuft forming position with the free ends thereof adjacent to said station, control means to act in two stages on the free ends adjacent to said station, said control means effective during the first stage to move said free ends adjacent to the backing fabric, the advancing means thereupon moving the carrier in tuft forming position with respect to the control means to pull off pile yarn, cutter means thereafter effective to cut the free ends from said carrier, said control means thereupon being effective during the second of said stages to insert the cut off free ends into that part of the ground fabric at said station, and the advancing means thereupon moving said carrier away from said tuft forming position and moving the next carrier in said series to said tuft forming position and the feed means moving another portion of the backing fabric to said station.

5. The machine set forth in claim 4- wherein the tuft pile yarns of each carrier are independent of the tuft pile yarns of the other carriers.

6. The machine set forth in claim 4 wherein the control means during said first stage holds the free ends against the ground fabric while the advancing means moves the carrier to pull off the pile yarn.

7. The machine set forth in claim 4 wherein the control means includes a set of teeth, one for each free end, to move the free ends against the ground fabric during said first stage and includes also a set of needles, one for each free end, movable from within the teeth to push the free ends into the ground fabric during said second stage.

8. The machine set forth in claim 4 wherein the cutter means includes a blade parallel to the carrier in tuft forming position and mechanism operative after the advancing means has pulled off pile yarn to move the blade laterally across all of the free ends to sever them from the carrier.

9. The machine set forth in claim 8 wherein the blade is stationary and the pile yarns extend across and in engagement with the blade when the advancing means is pulling ofi pile yarn and the blade cooperates with the control means to hold the pile yarn during the pull-01f operation of the advancing means.

10. The machine set forth in claim 4 wherein the machine has spaced guides and the control means during said first stage moves the free ends between said guides to preform tufts in said free ends prior to movement of the advancing means to pull off pile yarn.

11. The machine set forth in claim 10 wherein the guides and control means cooperate to hold the free ends frictionally during the pulling off of pile yarn by the advancing means.

12. The machine set forth in claim 10 wherein the control means during the second stage pushes the preformed tufts into the ground fabric.

13. The machine set forth in claim 10 wherein the cutter means is between said guides and the carrier in tuft forming position and the control means cooperates with the guides to hold the tufts during operation of the cutter means.

14. The machine set forth in claim 4 wherein the control means includes a set of teeth, one for each free end, to move the free ends against the ground fabric during said first stage and includes also a set of needles, one for each free end, movable to push the free ends into the backing fabric during said second stage.

15. The machine set forth in claim 14 wherein the machine has a support beam for the ground fabric hav ing recesses aligned with said needles and fins on the beam adjacent to the recesses support the backing fabric during the second stage of operation of the control means.

16. The machine set forth in claim 4 wherein the control means includes a set of teeth, one for each free end, which engage and move the free ends against the ground fabric during said first stage.

17. The machine set forth in claim 4 wherein the'control means includes a set of teeth, one tooth for each free end, and the carrier in tuft forming position includes a set of tubes, one for each free end, each tube having a part thereof in guiding position relative to the associated yarn and the teeth are separated by slots which receive said parts of the tube during the first stage of operation of said control means.

18. :In a machine for applying pile tufts to a ground fabric, a carrier provided with a supply of tuft pile yarns having free ends, means efiective to preform tufts in said free ends while the latter are attached to said supply, means thereafter effective to cut the preformed tufts from said supply, and mechanism thereafter effective to insert said cut preformed tufts into said ground fabric.

19. In a machine for applying pile tufts to a ground fabric, a carrier provided with a supply of tuft pile yarns having free ends, means to effect holding of the free ends while the latter are attached to said supply, means thereafter effective to cut the free ends from said supply, and means effective thereafter to push the out free ends in a direction from the holding means toward and into the ground fabric.

20. In a pile tuft yarn control means for a machine having backing cloth and free yarn ends to be incorporated into the backing cloth, support means for attachment to the machine, an elongated member having a set of transverse teeth, one tooth for each free end, mounted for movement on the support means in the direction of the length of the teeth, and a set of needles, one needle for each tooth, each needle deriving support from its tooth and slidable relatively to and guided by its tooth in said direction.

21. The control means set forth in claim 20 wherein the needles are slidable within the teeth.

22. A machine operating with the yarn control means set forth in claim 20 wherein two operating mechanisms are provided, one for each of said sets, said operating mechanisms causing the sets to move in unison toward the backing cloth during part of the operation of the machine and the mechanism corresponding to the teeth holding the latter stationary and the mechanism corresponding to the needles causing the latter to move relatively to the teeth into the backing cloth during another part of the operation of the machine.

23. The machine set forth in claim 22 wherein the operating mechanisms include two cams, one cam for each mechanism, fixed to a shaft which rotates during operation of the machine and wherein the contours of said cams are substantially the same for controlling said mechanisms during the first named part of said operation of the machine and wherein the contour of the cam for the mechanism corresponding to the set of needles differs from the contour of the other cam to cause said set of needles to move relatively to the teeth.

24. In a pile yarn control means for a machine having backing cloth and free yarn ends to be incorporated into the backing cloth, supporting means on the machine, tuft forming means including a set of teeth, one tooth for each free end, mounted for sliding movement on said support, and other means supporting a set of needles, one needle for each tooth, slidable within and guided by said tuft forming means for movement relatively to the latter, said tuft forming means by guiding said other means maintaining the needles in alignment with their respective teeth.

25. In yarn control and guide means for a machine zgs'eegeoo meanstomove saidtufiforming means away from *said guide means; the--tufts' remainingdn-saidguide -"means, and means thereafter effecting-relativemovement-between-- said guide means and thebacking cloth to e fiect-removal of the tuftsfrom the guide meansr 7 2,6z-The structure set forth in claim- 25 wherein the guide means is formedwith; achannel *for each tuft and the tuft formingmeans hasa toot-h to enter each-channel and cooperate -with thejguide-means to; preform thetufts: 27: The structure set forthin-claim'25'-'wherein theguide means includes two spaced-bars betweenwhich the tuft-formingrneans moves whenpreforming thetufts, and wherein means are provided-tqrotate -said;barsto effect removal of the tufts'frombetweeirsaid-bars: 281; The structure-set-forth inclaim -25 wherein said guidemeans includes -two-spaced bars connected by a plurality ofwebs which define apluralityof channels-between the bars and *wherein the tuft forming meanshas a tooth toenter each channel to preform-the tufts and wherein means are provided-to give said guide'means a one-half rotation after the tuftformingtmeans has 'moved away from the guide means tOBfifiCtICIIlOVEIlOf the tufts-from the channels.

29 The structure set forthin claim 2 5 wherein the backing cloth moves progressively in a givendirection to move a row of tufts attached thereto away fromatuft form-ing station and wherein the guide means includes two-spaced bars between which the rowof tufts extends and wherein means are provided to turn'said bars in such manner that the parts of'thebars adjacent-to said cloth movein-thesame direction, as the cloth moves -when-moving the-row of tufts away from said station.-

30. The structure setforth in claim 25 wherein" the tuft formingmeansmoves in a straight'line toward-andfromthebacking cloth-incident topreforming thetufts and wherein means are provided to rotate said guide means to effect disengagement w-ith the 'rowof tufts an angular distance equal to at least'a one-halfrotatidn thereof. a

31. In amachinefor applying-pile tufts to a backing fabric at a tuft'forming station, a-feed system'advancing a backing cloth at-regular intervals, a guide-beam across which the backing-cloth moves-.towa-rd and front-said station, said-beam having an upper plate inclinedtdowm wardly -and forwardlytoward; said station-and: having at lower plate inclineddownwardly and rearwardlyi from said station and h'aving a rounded nose-joining said plates a plurality of spaced recesses in;said,nosearrangedhorizontally along said stationwacross which the; cloth.jex-

tends, the :beam having cloth supporting'tpartsbetween said .recesses, and mechanism comprisingyra; plurality; ofneedlesnaligned'with the, recesses effective-to push pile 12 tufts; into those partsof the cloth filiflfidfWlththe re cesses and-intq-the-recsses between-said cloth supporting parts of the beam; t

32, The machine set forth in claim 31 wherein the beam is provided with grooves aligned with said -recesses extending in the directionof travel of -the cloth to receive thoseparts of the tufts which have beeninserted into the backing clothas'the latter moves with respectv to the beam: 7 i

33. In a yarn carrier for a tuft forming machine-where in tufts are applied to a backing cloth by a set of teeth; movable in a direction toward-the cloth; a lengthwise bar, a spool having a plurality of yarns wound thereon'f rotatably mounted on the bar,-yarntubes securedto the" bar extending transversely with respect thereto and from;

which freefends 'of-the yarns extend, said; yarn'tubeshaw ing the ends thereof'r'emote from the spool formed withf lateral guides substantially parallel to'said direction of movement of the teeth to hold 'said free ends in position 34. Ina machine for applying pile tufts to arcloth backing, a'pair of transporting chains, movable in. unison,;; a plurality of yarn carriers remaining connectedi tosaidj chains at spaced intervals, therealong during operation]; of the machine, said carriers having free yarn ends,ex-

tending therefrom, yarn cont'rolmeans movable between two adjacent carriers on said chains' toinsert the free ends-ofone of said two carriers into the backing cloth;

35. A machine set forth in, claim 34. wherein saidyarn control meansafter inserting the free ends int q the backing cloth moves out offapositionbetween said; two carriers and advancing means thereafter moves the] chain to present another yarn carrier in position for its free ends to be attached to the backing cloth by the yarn control means.

36. The methodof attachingpile tuftsfto a backing;

cloth'in such manner as tov produce a tufted pattern,.,saidl method including the following steps; winding aplura itya of spools withyarns arrangeduthereon with respt t ttoeach other in an order corresponding to the pattern, drawing oi the yarns, of each spool ;to form arrow of freeyarnj ends, moving said spools successivelyto present said rows of ends one at a time in a tuft forming position, thereafter, cutting said row of free ends in said position from. the corresponding spools, and thereafter inserting he cut row of free ends into the ,backingcloth v Th method se for h in 1 im;,36 wherein the free; ends are preformed into tufts before being cut from the.

spools,

References Cited in the file of this patent UNITED STATES PATENTS 876,562 Kleutgen Ian.- 14,: 1908": 1,757,795 Dahlen; May-6,715 305? 1,997,869 Loos Apr: 16, 1935'; 2,595,585 Kline May .6,- 1952 

